Apparatus for winding a running length of thermoplastic sheeting into a series of rolls

ABSTRACT

A system and method for automatic handling a running length of thermoplastic sheeting to form a series of individual rolls wherein the method comprises collecting the running length of sheeting, moving a core containing a certain length of sheeting away from the general path of movement of the sheeting, moving an empty core into the general path of movement of the sheeting, severing the sheeting and heat bonding the end of the running length of sheeting to the empty core and winding the running length of sheeting on the empty core; and wherein the system comprises basically an accumulator unit, sheet forwarding means, windup promotion means, windup unit, and severing unit all cooperating through a control means to accomplish the primary objective. Rolls of sheeting made from the system and method.

United States Patent [191 Davis [4 1 Mar. 12, 1974 [75] Inventor:Douglas Steward Davis,

ParkersFurg, W. Va.

[73] Assignee: E. I. du Pont de Nemours and Company, Wilmington, Del.

22 Filed: July 23,1970

21 App1.No.:57,678

[52] US. Cl. 242/56 A, 206/59 C, 242/64 [51] Int. Cl B65h 19/26, B65h19/28 [58] Field of Search 242/56 A, 56 R, 64, 74,

2,860,839 11/1958 Bower 242/56 A Primqry xaminer- -George F. Mautz 5 7]ABSTRACT A system and method for automatic handling a running length ofthermoplastic sheeting to form a series of individual rolls wherein themethod comprises collecting the running length of sheeting, moving acore containing a certain length of sheeting away from the general pathof movement of the sheeting, moving an empty core into the general pathof movement of the sheeting, severing the sheeting and heat bonding theend of the running length of sheeting to the empty core and winding therunning length of sheeting on the empty core; and wherein the systemcomprises basically an accumulator unit, sheetforwarding means, winduppromotion means, windup unit, and severing unit all cooperating througha control means to accomplish the primary objective. Rolls of sheetingmade from the system and method.

1 Claim, 7 Drawing Figures PATENIEI] IIAR 1 2 I974 SHEEI 1 0F 5 FIG-1AGENT FIG-3 INVENTOR DOUGLAS STEWARD DAVIS AGENT PATENTEB III! I 2 B74SHEET [IF 5 FIG-6a INVENTOR PS-l DOUGLAS STEWARD DAVIS AGENT PATENTEBMR12 1914 3.796388 sum 5 or 5 F l G 6 b E PS-7 INVENTOR DOU GLAS STEWAR DDAVIS BY M L M AGENT APPARATUS FOR WINDING A RUNNING LENGTH OFTHERMOPLASTIC SHEETING INTO A SERIES OF ROLLS BACKGROUND OF THEINVENTION This invention relates to a system and method forautomatically winding into a number of rolls a running length ofthermoplastic sheeting. Particularly, this invention relates to a systemfor automatically moving a full roll of sheeting out of the windingposition, heat bonding the severed end running length of sheeting to anempty core and moving the empty core into position for winding. Moreparticularly, this invention relates to a roll of sheeting madeutilizing the automatic system which comprises the core and a pluralityof layers of sheeting adjacent thereto with the end of the firstadjacent layer of sheeting being heat bonded to the core.

It is known that sheeting can be attached to cores l) by wrapping thesheeting around the core such that the end of the sheeting which isadjacent to the core is caught under the next layer of sheeting andtherefore thevsheeting is held fast to the core and (2) by gluing theend of the sheeting to the core. It is also known that thin sheeting upto about 0.75 mil can be cut with a hot wire cutter and mechanicallystarted on an empty core (U.S.Pat. No. 3,091 ,41 l Turret type windersare also known.

The known methods of attaching sheeting to a core were found to beinadequate in that the gluing was not flexible in that it could not beused with sheeting which was covered with powder, etc. and thecatch-type methods of securing the sheeting on a core frequentlyinvolved a fold-back forming at the point where the end of the sheetingwhich is adjacent to the core is overlapped by the second layer ofsheeting. This fold-back caused a great deal of waste, i.e., about -15layers of sheeting since the sheeting would be unduly stressed at thepoint of overlap of the fold-back. Further, even when there was nofold-back, a sharply cut end of sheeting would cause stresses in anumber of adjacent layers such that they had to be discarded.

A system, method and resultant roll were sought which would (1) allowone to cut a running length of sheeting and secure the sheeting on anempty core without stopping the continuous flow of sheeting through aprocessing unit, (2) avoid the waste from fold-back and from the sharpedge on the end of the sheeting, and (3) allow for automatic changingfrom a full to an empty core.

SUMMARY OF THE INVENTION A system has been found which fulfills theabove requirements. It is a system for automatic handling of a runninglength of thermoplastic sheeting from a processing unit to form a seriesof individual rolls'which comprises in combination an accumulator unitcooperating with the processing unit and positioned along the generalpath of movement of the sheeting; sheet forwarding means cooperatingwith the accumulator and positioned along the general path of movementof the sheeting; windup promotion means cooperating with the sheetforwarding means and positioned along the general path of movement ofthe sheeting; a windup unit cooperating with the windup promotion meansand positioned along the general path of movement of the sheeting, saidwindup unit comprising means for moving a core containing a certainlength of sheeting away from the general path of movement of thesheeting and replacing said core containing a certain length of sheetingwith an empty core; and a severing unit cooperating with the windup unitand positioned along the general path of movement of the sheeting, saidsevering unit comprising means for severing the sheeting and heatbonding the end of the running length of sheeting to the empty core;saidI accumulator unit, sheet forwarding means, windup promotion means,windup unit, and severing unit cooperating through a control means tocause the accumulator unit to collect the sheeting from the processingunit which continues to operate while the core containing a certainlength of sheeting is automatically moved from the general path ofmovement of the sheeting, the sheeting severed, the end of the runninglength of sheeting heat bonded to the empty core and the empty coremoved into the general path of movement of the sheeting.

Also included in the invention is a method for utilizing the system anda roll of sheeting made therefrom. The method is a method forautomatically changing from a core containing a certain length ofthermoplastic sheeting to an empty core when winding a running length ofsheeting into a series of rolls which comprises (a) collecting therunning length of sheeting, (b) moving the core containing a certainlength of sheeting away from the general path of movement of thesheeting, (c) moving the empty core towards the general path of movementof the sheeting, (d) severing the sheeting and heat bonding the end ofthe running length of sheeting to the empty core, and (e) winding therunning length of sheeting on the empty core. The roll of sheeting isdescribed later.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a partial over-all side viewwith some parts in section of the windup unit and severing unit showing(1) their relation to the accumulator unit, windup promotion means, etc.and (2) the various positions of the windup unit and severing unitduring the automatic roll change.

FIG. 2 is a partial view of the windup unit and severing unit with someparts shown as cut-a-ways viewed from the general path of movement sideof the windup unit.

FIG. 3 is a partial cross section of the severing end of the severingunit and core in position for severing the sheeting and heat bonding.

FIG. 4 is a partial cross section of the severing end of the severingunit and core in position during cooling after severing and heatbonding.

FIG. 5 is a partial cross section of the core containing layers ofsheeting showing the bond of the end of the first adjacent layer ofsheeting to the core.

FIGS. 6a and 6b are partial schematics and diagrammatics of the fluidpressure control, operating systems and cooperating machine componentsof a preferred apparatus embodying the principles of the invention.

DESCRIPTION OF PREFERRED EMBODIMENTS A partial over'all side view of thesystem is shown in FIG. 1 with parts in section. Unit I is theaccumulator unit which receives the sheeting from the processing unit(not shown). The accumulator unit is utilized to collect the sheetingflowing from the processing unit and allow it to operate while thewindup unit 3 and severing unit 4 are accomplishing the core changeduring which time the flow of sheeting to the windup unit is for themost part nonexistent.

Unit 2 which is in the general path of movement of the sheeting betweenthe accumulator unit 1 and the windup unit 3 can be a number of orcombinations of items including sheeting forwarding means, i.e., driverolls; a slitter to trim the edge of the sheeting; and a series of rollsto produce the correct amount of tension in the sheeting and therebypromote windup.

Unit 5 is a rider roll which is useful in promotion of windup. It liftsso as to be out of the general path of movement of the sheeting duringthe core change operation and does not go down to normal operatingposition until the empty core is in normal winding position. The riderroll consists of the roll 6 and means for holding it and moving itsposition 7. The rider roll smooths the sheeting as it is placed on theroll and assists in providing the proper tension in the sheetingforwinding in the windup unit.

Unit 3 is the windup unit and comprises a rotating turret 8 moved bymotor 9 and drive means 10, supported by and rotating with shaft 11which is supported by bracket 12, supported by supporting frames 13 and14. The rotating turret 8 comprises two spindles 15 and 16'which containair operated chucks 17 and 18 for holding the cores l9 and 20, 20contains a certain predetermined length of sheeting and drive (21,22)means for rotating the chucks l8 and 19 which are driven by motors 23and 24 held in position by motor mounts 25 and 26 on shaft 11. The airoperated chucks are operated by air lines 27, 28, 29 and 30, each airline being represented by a single line.

FIG. 1 indicates the 4 positions of the empty core or core containing acertain length of sheeting (full roll) during normal operation andduring the severing and heat bonding of the sheeting. Position 1 iswhere the full roll is when the core is in normal winding position(position 3). The full roll at position 1 is dropped off at that pointand replaced by an empty core ready to replace the core which is beingfilled in position 3. The sequence of oeprations which occurs in thewindup unit during a core change is discussed below and uses as itsbeginning point in the sequence as the point where the core is beingfilled as in position 3 and the previously filled full roll which was inposition 1 has been replaced by an empty core.

When it is indicated that the core in position 3 contains a certainlength of sheeting, the turret 8 rotates the core from position 3, 270,to position 2, thereby, placing the empty core in position 4. Therunning length of sheeting after the 270 rotation is shown by line 31which indicates that it overlaps the core 19 (empty) in position 4 andis still continuous with the sheeting on the core containing the certainlength of sheeting in position 2. After severing and heat bonding inwhichthe severed end of the sheeting attached to the core containing thecertain length of sheeting drops and the severed end of the runninglength of sheeting is heat bonded to the core, the turret 8 rotates 90such that the empty core with the running length of sheeting heat bondedto it is in position 3 and the roll containing thecertain(predetermined) length of sheeting is in position 1 where it isto be replaced by an empty core.

Unit 4 is the severing unit which severs and heat bonds the sheeting tothe empty core. Supporting frame 32 and beam 33 support eyes 34 which inturn support shaft 35 which holds and allows arm 36 to move via aircylinder 37 which is operated by air lines 38. The air cylinder 37 issupported by beam 33 and bracket 39 and is connected to arm 36 byconnecting means 40. Arm 36 holds among other things the severing member(wire) 41 and clamp 42 which is operated by air cylinders 53 fed by airlines 44 which are in turn fed by air supply 45. The clamp 42 andsevering member 41 are enclosed by rubber aprons 46 and 47.

Air supply 45 also feeds via lines 48 air jets which are not shown inFIG. 1. The rest of the description of the severing end of the severingunit is reserved for more detailed FIGS. 2, 3, and 4.

FIG. 1 indicates the two positions of the severing end of unit 4, i.e.,the severing unit which are position A which is the position duringnormal winding and position. B which is the position during severing andheat bonding. In position B, the severing end of the severing unit is inoperative association with the sheeting and empty core. The heatingmeans for the severing member 41 is not shown in any of the Figures andis a means for carrying current to severing member 41.

The severing end of the severing unit 4 is in position B part of thetime when the core (empty) is in position 4 and the core containing acertain length of sheeting is in position 2. When the turret 8 isrotating or in position so the cores are in positions 3 and 1, thesevering unit 4 is in position A. FIGS. 3 and 4 give detailed depictionof the severing end of the severing unit while in position B.

FIG. 2 is a partial view of the windup unit 3 and severing unit 4 lookedat from the path of movement of the sheeting. The turret 8 is inposition such that spindles 15, 15', 16 and 16 containing air chucks 17,17, 18 and 18' fed by air lines 27, 28, 29, 30, 27, 28, 29 and 30 aresituated with spindles 15 and 15 in position which corresponds toposition 4 of FIG. 1 and 16 and 16' in position which corresponds toposition 2 of FIG. 1. The air chucks 17 and 17 are rotated by drivemeans 21, powered by motor 23 which is supported by motor mount 25.Motor 24 powers drive means 22 which rotates air chucks 18 and 18. Theturret 8 is supported by and rotates with shaft 11, which rotates inbearing means 49 and 50, is supported by brackets 12 and 12 held bysupporting frames 13, 13, 14 and 14', and is rotated by drive means 10powered by motor 9.

Supporting frames 13, 14, 13 and 14' also support the severing unit 4through support frame 32 and 32 and beam 33 which holds eyes 34 and 34'which support and allow shaft 35 to rotate. Shaft 35 supports the arm 36of the severing unit 4. The arm 36 holds air cylinders 43, clamp 42, airjet 51, air line 44 to the air cylinders 43, air lines 48 to air jets51, holding means for the severing member 52, severing member 41 andrubber aprons 46 and 47. The air lines are supplied by air supply 45.The arm 36 is moved to and from the severing and heat bonding positionby connecting means 40 driven by air cylinder 37 supported by bracket39.

The air cylinders 43 are attached via their plunger 53 to the clamp 42and move the clamp into operative association with the sheeting andempty core during the severing and heat bonding of the sheeting to thecore. The clamp 42 extends the length of the severing member 41. Theclamp 42 and air jets 51 are shown in detail in FIGS. 3 and 4.

FIG. 3 is a cross section of severing end of the severing unitindicating its position at the point of severing and heat bonding. Therubber aprons 46 and 47 enclose the clamp 42 which consists of a rubberlayer 54 backed by a metal layer 55 and is attached to a plunger 53 froman air cylinder 43 which moves the clamp 42 in operative associationwith the sheeting 31 and core 19. The clamp 42 holds the sheeting 31 inplace during the severing and heat bonding.

The rubber aprons 46 and 47 also enclose the holding means 52 for thesevering member 41, i.e., severing wire. The holding means 52 issupported by support frame 56 while the air cylinder is supported bysupport frame 57. The clamp 42 operated by the air cylinder 43 and itsplunger 53 along with the support frame 56 and holding means 52 keep thesevering member 41 in operative association with the sheeting and core,i.e., in contact with the sheeting core and sheeting during the severingand heat bonding of the sheeting. The heating means for the severingmember is electrical and is not shown.

FIG. 3 is the position of the severing end of the severing unit from thetime the severing end of the severing unit is initially lowered to thesheeting and core until it is raised a small amount with the clampholding its position for cooling. This position is shown in FIG. 4.

FIG. 4 depicts the aforesaid portion of the severing end of the severingunit. Once again the rubber aprons 46 and 47 enclose the clamp 42consisting of the rubber layer 54 and metal backing layer 55 attached tothe plunger 53 of the air cylinder which is not shown. In this position,however, the severing and heating bonding have taken place and thesevering end of the severing unit has been lifted a small amount, aboutan inch with the plunger 53 of the air cylinder extending so as tocontinue to hold the running length of sheeting 31 to the core byholding at a point near the end of the running length of sheeting 31into the core 19 so that the end 31 of the running length of sheetingwhich has just been heat bonded to the core via the severing member 41,the severing member being held by the holding means 52 which issupported by support frame 56, can have sufficient time to form a solidbond with the core. The formation of the solid bond is promoted bycooling from air which is provided by air jets 51 supported by supportframe 57 with the flow of air shown as 58. The flow of air continues onthe heat bond and the severing end of the severing unit stays in theposition depicted in FIG. 4 until it is indicated that the accumulatorunit is'sufficiently full, i.e., about 75 percent full and then thecooling stops and the clamp 42 lifts while the entire severing end ofthe severing unit is moved away from the core 19. The recently severedend of the sheeting 31" which is attached to the core containing acertain length of sheeting (not shown) drops away from the core 19 assoon as the severing is complete which is prior to the cooling via theair jets 51. A detailed description of the sequence of events isdescribed later in the discussion of schematics 6a and 6b.

FIG. 5 is a partial cross section of a core 20, the first adjacent layerof thermoplastic sheeting 31 which has the tapered end 31 heat bonded tothe core. The tapered edge causes less stress at the point on the layersof sheeting 32" where they overlap the heat bonded, tapered end of thesheeting.

The entire roll of thermoplastic sheeting of which FIG. 5 is a partialcross section comprises (a) a core 20, (b) a first layer of sheetingimmediately adjacent thereto 31, said first layer being heat bonded tosaid core by a heatbond 31' between at least a portion of the end ofsaid first adjacent layer 31 and said core and (c) a plurality of layers31' of sheeting continuous with and adjacent to said first layer. Thebond between the first layer and core is tapered to an extent that lessthan about 6 of the adjacent layers of sheeting overlapping said bondare stressed to such an extent at the point of overlap that there is avisible optical distortion relative to the remainder of the sheeting.The tapering of the bond is normally accomplished by utilizing asevering member which has a solid cylindrical cross section althoughmembers with other cross sections can be utilized. Many sizes and shapesof severing members are useful but a particularly useful wire for 15 milto 40 mil sheeting is about 0.1 inch diameter wire.

The composition of the core can vary and is not cirtical. A preferredcore is one which is annular and contains an inner and outer cardboardlayer with a layer of aluminum between them. The length of the core isnot critical but normally runs from about 20 to about 45 inches with thepreferred being about 30 inches. The diameter of the core is also notcirtical but normally varies from about 3 to about 8 inches outsidediameter.

The sheeting in the roll of sheeting is thermoplastic and can be manyvarious types of sheeting. The preferred types are polyvinyl butyral,plasticized polyvinyl chloride, polyurethane, ethylene/vinyl acetatecopolymers and hydrolyzed ethylene/vinyl acetate copolymers. Thesheeting may be coated with powder such as sodium bicarbonate, potassiumbicarbonate, etc. if the properties of the sheeting are such that it isnecessary to allow the sheeting to be conveniently handled.

FIGS. 6a and 6b are a partial schematic of the control system, i.e.,control means which causes each of the parts of the system describedabove to operate automatically in a sequential manner to form the abovedescribed rolls of sheeting. FIGS. 6a and 6b show the position of thevalves when the system is running at normal winding and is ready tobegin an automatic roll change. This is evident by the diagrammaticrepresentation of the rider roll 6 and its holding means 7 indicatingthat it is down in the normal winding position on top of the core beingwound 20, held by spindle 16 which is in the normal winding position,position 3 of FlG. 1.

Throughout the discussion of the schematic the following will alwayshold: (1) if there is an S leading into the switch, valve, etc., thismeans that they are constantly supplied with air from a main airmanifold, (2) thew. indication on a valve, switch, etc. indicates thatit has a spring return and will return to the position opposite to thespring when the force causing it to move towards the spring is removed,(3) E means that the valve, switch, etc. is supplied constantly withelectricity from a main supply line, (4) when the arrow in the switch,valve, etc. is directed towards a wall with no outlet, this means thevalve is plugged in that position, and (5) the arrow in an air relaystays at the last position to which it is moved until it is moved byanother surge of air.

If the cycle is entered at the point where the operator has just removedthe full roll (core containing a certain (predetermined) length ofsheeting) and replaced. it with an empty core, this being the onlymanual operation if the system is running on its automatic sequence; itis found that the first step in the cycle is the operator pushingspring-return air switch D1. The pushing of D1 sends a surge of airpressure to R1, and air relay, which causes the arrow in R1 to shift sothat air is flowing through R1 to P1, this will continue until the arrowof R1 is shifted back by air from spring-return air valve Tl which isactuated by a cam sequencer via Tls cam follower on the left side ofvalve T1. T1 is supplied with air from air relay R which always has itsarrow up during the normal automatic cycle. The shifting of the arrowsof R1 by T1 occurs shortly after the empty core 19 held by spindlereaches the cutting position indicated diagrammatically in FIG. 6b.

Therefore, in the cycle at this point air is flowing through R1 to P1, aspring-return air valve, causing the arrow of P1 to shift so that aircan flow through. No air flows until the footage counter via theelectrical signal at (3-1 shifts the spring-loaded solenoid valve SV-lso that air is flowing through it. It does this when the footage countercounting the length of sheeting winding on to the core indicates that acertain predetermined amount of sheeting has been wound on the core. Theair flowing through SV-l flows via .L to the accumulator to start itcollecting the sheeting, via L to the sheet forwarding means between theaccumulator and windup unit to stop its operation, and up to shuttlevalve V1 which allows flow to the right but not to the left when thereis air pressure from SV-l.

Since P1 has its arrow moved so that it is opened, the air flows throughit to spring-return air valve P2 which has its arrow such that it allowsthe air to flow through to air relay R2. The arrow in P2 is down sinceit is pushed down by air from spring-return air valve T2 which issupplied by air relay R3. T2 has its arrow in position to allow air toflow through when the end of a cycle has been reached and it is readyfor another cycle to begin. R3 has its arrow to the left at all timesexcept when a repeat cut is required. T2 is actuated by a cam sequencerwhich has 2 lobes on it for T2 so that the arrow in T2 is to the rightat the beginning of the cam sequencer cycle and when the cooling cycleis taking place.

The air from P2 then has reached R2 causing R2s arrow to go down andallow air to flow through it. The arrow stays down until lifted by T1which occurs at the same time that R1 is shifted as was described above.The air flowing through R2 flows to spring-loaded solenoid valve SV-2and to air relay R4. Nothing happens to SV-2 at this point because itsarrow has not been shifted by the empty core reaching the cuttingposition. R4, however, has its arrow shifted to the bottom position viaair flowing from R2 through V2 and air flows into cylinder 59 causingpiston 60 to lift the rider roll 6, all of which are showndiagrammatically.

When the rider roll 6 reaches the position for the core change, thepiston 60 comes in contact with the ball follower of spring-return airvalve T3 shown as the projection on the right side of air valve T3. Thiscauses the arrow in T3 to shift to the left and for the air which isflowing through spring-return air valve T4 which has its arrow to theright since its ball follower is in contact with the piston 61 incylinder 37 of the severing unit, both of which are showndiagrammatically. The air to T4 is supplied through air relay R5 whichhas its arrow pointed up at all times while the system is in normalautomatic mode.

T3 has air flowing through it since the rider roll is up. The rider rollhas stopped since the piston 60 has come against a mechanical stop, thetop of the cylinder 59 and is being held there by the preseure of thesystem.

The air through T3 flows to pressure-operated electrical switch PS-lwhich has electrical current to it from (1-1 which indicates the corecontains a certain length of sheeting. The pressure from T3 whichindicates the rider roll is up (out of the general path of movement)causes the needle in PS-l to shift to the bottom position which giveselectrical current flow through PS-l. This causes an electrical signalH-l to cause the turret to rotate 270 in the direction such that thecore containing a certain length of sheeting is moved away from thegeneral path of movement of the sheeting while the empty core rotates270 to a position under the severing unit. The electrical signal H-lalso causes the roll containing a certain length of sheeting to windbackwards paying out slack while it is moving from the general path ofmovement of the sheeting, the payed out sheeting overlaps the empty corewhen the movement is complete.

T3 also sends pressure to a spring-return air valve T5 which is camoperated. Since it is not operated until later in the cycle, air doesnot flow through T5.

When the core containing a certain lengthof sheeting reaches electricallimit switch LS-l at the end of the 270 rotation of the turret, itshifts the needle in LS-l so that current flows through LS-l toelectrical relay J1 which causes its needle to move up and allow currentto flow through J1. (J1 is reset to the bottom off position by theelectrical system through EE when the empty core after severing and heatbonding begins to move to the winding position). The current through J1gives a current source to electrical limit switch LS-2 which causes themotors to stop the rotation of the turret via I-l-2 when the spindlecontaining the empty core contacts the contact follower of LS-2 whichindicates it is under the severing unit. Electrical current also flowsthrough LS-2 to electrical limit switch LS-3 which causes current toflow through if one spindle is at the severing unit, and the contactfollower is not contacted, this beingindicated to the electrical systemvia H-3. If the contact follower of LS-3 has contact, the needle movesto the right and indicates to the electrical system through H-4 via aflow of current that the other spindle is at the severing unit. This isnecessary so that the electrical system will cause the correct core torotate when winding is called for.

The current from LS-2 also causes switch SW to close indicating that allmotors are off. This causes the arrow in SV-2 to be moved down and sinceSV-2 has an air supply from R2, air is supplied to spring-return airvalve T6 which allows the air to flow to springreturn air valve T7. Theair stops at T7 until its arrow is shifted by the cam sequencer.

Air also flows from SV-2 to air shuttle V3 and on to spring-return airvalve T8 and air relay R6. The air flowing to T8 causes its arrow to beshifted to the left which vents the left side of R6 via line II. The airflowing from SV-2 to R6 causes its arrow to be shifted from brake 12which is the brake on the cam sequencer to the left which causes the airto flow to air relay R7 which has its arrow to the left causing the camsequencer to run at normal speed via line l3.

The first function of the cam sequencer is to contact the cam followeron spring-return air valve T9 which is supplied by R3, R3 having itsarrow to the left. T9s arrow is shifted to the right and air flowsthrough air shuttles V4 and V5, through spring-return air valve T10 topressure-operated electrical switch PS-2. This causes the needle in theswitch to come down and electrical current to flow via H- to theelectrical system which causes the correct spindle motor via H-3 and H-4to rotate the empty core so as to clean the powder off the sheetingwhich is overlapping the empty core as a result of the 270 rotation ofit and the core containing a certain amount of sheeting via the turret.This particular embodiment is concerned with winding sheeting coveredwith powder. The spring on T9 causes the arrow to move back to the leftafter the lobe on the cam passes and then the rotation of the coreceases.

After the core is rotated to clean off the powder on the sheeting, thecam sequencer actuates spring-return air valve T7 causing its arrow toshift left. This sends air through air shuttle V6 to air relay R8causing the arrow in R8 to be shifted up causing air to flow intocylinder 37, pushing piston 61 down causing the severing unit to movedown towards the core. When the severing end of the severing unit getsdown to its proper position in operative association with the empty coreand the sheeting which is overlapping it, its piston actuates the ballfollower on spring-return air valve T11 which has its arrow shiftedright causing air to flow first to air relays R9 and R10. This causesthe arrow in R9 to shift up but no air is being supplied to R9 at thispoint so nothing flows through .it. in R10, the air from T11 causes thearrow to shift down, causing the clamp to close via l4 and also air tobe supplied to spring-returnair valve T12 which has its arrow to theleft which is the plugged position. The clamp holds the sheeting inoperative association with the empty core. The severing member is inoperative association with the sheeting and empty core.

Air is also being supplied from T11 to pressureoperated electricalswitches PS-3 and PS-4. This causes the needle in PS-3 to shift down andstart the means for heating the severing member heating via line H-6.The needle in PS4 is also shifted down and this starts the dwell timertiming via 1-1-7. The dwell timer via an electrical signal through G-2causes the arrow in solenoid valve SV-3 to shift down. .The heating ofthe severing member causes the sheeting to be severed, the newly severedend ofthe running length of sheeting to be heat bonded to the emptycore, and the end of the sheeting which is attached to that wound onthecore containing a certain length of sheeting to drop away from theempty core.

Air from T11 is allowed to pass through spring-return air valve T13 whenits cam follower is actuated by the cam sequencer immediately after thecam sequencer has finished actuating T7. The air flowing through T13 isthe air supply for solenoid valve SV-3. The dwell timer causes the arrowin SV-3 to be in the down position until the dwell period has ceasedindicating that heating is over via line G-2 from the electrical system.T13 is actuated by the cam sequencer and air flows to SV-3 before thedwell period is over. When dwell is over, the arrow on SV-3 shifts upand air flows through air shuttle V7 to V16 and to the top of R8 causingthe arrow in R8 to be shifted down and the air from the top of thecylinder 37 to be vented off.

The shifting of the arrow in R8 causes air to flow into the bottom ofcylinder 37 causing the piston 61 to be lifted; thereby lifting thesevering unit. The severing unit lifts until it contacts the contactfollower on T12 which causes its arrow to be shifted to the rightcausing air to flow to R9 which has its arrow up allowing air to flow toR8. This causes air to flow to the top of piston 61 while air is alsoflowing to its bottom and therefore the piston stops at this point. Atthis point the severing member is about an inch above the empty core andthe clamps have extended thereby continuing hold the sheeting to thecore. The sheeting has been severed and the end of the continuoussheeting heat-bonded to the core.

The air flowing from the outlet of R9 also flows to air relay R11 whichcauses its arrow to shift down causing the cooling air jets to come onvia 15. The cooling blast of air is directed to the heat bond betweenthesheeting and the core. The air cooling continues until the accumulatortrips the contact follower on spring-return air valve T14 which gets itsair supply from the accumulator control system via U indicating theaccumulator is full to a certain predetermined degree. This causes the.

arrow in T14 to shift right causing air to flow to air relay R12 causingits arrow to shift left causing air to flow through it, through airshuttle V8 to R9 causing its arrow to shift down thereby allowing thesevering unit to rise via the air pressure on the bottom of cylinder 37pushing up piston 61. Air flows from R12 through V8 and V7 to R8 tocause its arrow to move down in case it is not down already which itnormally would be at this point in the cycle.

Air from R12 also flows to R10 causing its arrow to be shifted upthereby causing the clamps to be opened via 16 and to R11, causing itsarrow to be moved up to the top position thereby shutting off thecooling air jets. A pulse of air also flows from R12 through air shuttleV5 through T10 and to PS-2 and causes its needle to be shifted downcausing the core to rotate via H-5 and take up the slack in thesheeting. This is a predetermined amount set by the electrical system.

Air from R12 also flows via V3 to T8 and R6 to start the cam sequenceroperating again via R7 at normal speed 13. The cam sequencer was shutoff by the above described second lobe on the cam sequencer foractuating T2 which actuated T2 during the cooling part of the cycle.SV-2 lost its air when T1 was actuated as described above and thereforethere was no resistance to T2 stopping the cam sequencer when it wasactuated.

At this point when the severing unit reaches its top position out of thegeneral path of movement of the sheeting, it contacts the ball followeron T4, thereby, causing its arrow to shift right (ithaving shifted leftwhen the severing unit went down) and causing air to flow'to T3. Thearrow in T3 is to the left because the rider roll is up; therefore, theair flows through T3 to T5. The air also pushes the needle in-PS-l downbut since there is no signal from the footage counter via G-l, no signalpasses out H-l.

Therefore, air is flowing to T5. The cam sequencer actuates the camfollower on T5 causing the arrow to shift left. This causes air to flowto pressuraoperated electrical switch PS-S causing the needle to movedown causing electricv current to flow via line 1-1-8 to cause the motorwhich rotates the turret to rotate it in the direction toward thegeneral path of movement of the sheeting such that the empty core isrotated into winding position and the core containing a certain amountof sheeting is in position for removal' The rotation is stopped when thespindle containing the empty core contacts the contact follower ofelectrical limit switch LS-4 causing its needle to shift left andelectric current to flow via line 11-9 to stop the movement of theturret.

The electric current also flows to electrical limit switch LS- whichindicates to the electrical system via H- or H-ll which spindle is inwinding position. If it is one, it will cause the contact follower ofLS-S to cause the needle to shift left and current to flow through H-10.If it is the other, the needle will stay as is, and the spindle will beindicated by l-l-l 1.

Electric current from LS-4 also flows to solenoid valve SV-4 whichcauses its needle to move down so that air flows through it tospring-return air valve T15. The cam sequencer has moved the arrow in Tto the right so air flows through it and through shuttle valve V9 to R4thus causing its arrow to move back to the up position causing air tofill the upper portion of cylinder 59, pushing piston 60 down. Thiscauses the rider roll 6 to move down.

When the rider roll gets to the proper position for winding on top ofthe core, it stops and piston 60 contacts the contact follower ofspring-return air valve T16 causing its arrow to be shifted to the right(this can only happen if there is an empty core) causing air to flow viaV14 to pressure-operated electric switch PS-6 which causes its needle tomove down so that electrical current is sent via 1-1-12 to the correctmotor to rotate the empty core at overspeed. 1-1-12 also starts thesheet forwarding means between the accumulator unit and windup unitoperating. The electrical system which causes the core to rotate atoverspeed via 1-1-12 causes it to rotate at overspeed until accumulatoris emptied to a predetermined degree and then gradually slows to normalline speed at which point the accumulator is empty and the cycle iscompleted.

SU is an air throw switch which puts the system in mode for a normalautomatic repeat out if set so that the air flows from the top outletline to spring-return air valve T17 which is actuated by the camsequencer immediately after T1 is actuated. It allows for a repeat cutfor a certain predetermined period.

The air flows from T17 to air switch D2 which is the switch whichactuates repeat cut. If it is pushed, air flows to R3 causing its arrowto be pushed to the right. This causes air to flow to spring-return airvalve T18 which causes the empty core to rotate via PS-2 so that the cutis not in the same position on the core. The air from D2 also shifts thearrow in R7 to the right causing the cam sequencer to operate ataccelerated speed via 17. Air passes from R7 through air shuttles V10and V8 to put the arrows in the severing unit controls R9 etc. inposition as though the normal cutting sequence is over, i.e., in theirnormal winding positions. The air from D2 also causes R5 to have itsarrow shifted down thus putting the rider roll on manual control via airswitches D3 and D4. The air from R5 also flows via Q to air switches D5which flows through air shuttles V15 to D5 and D6 which allows formanual operation of the severing unit. The manual control put on therider roll and severing unit are on so that they will not operate whilethe cam sequencer is at overspeed. The cam sequencer contactsspring-return valve T19 when the overspeed cycle is almost completed sothat R7 is put back into position for normal operating speed and manualcontrol is removed.

A safety device in the system is spring-return air valve T which isactuated by the cam sequencer and will cause the severing unit to comeup if via T11 it is found that the core containing a certain amount ofsheeting is in the severing position when the severing unit is lowered.This is possible because if T11 hasn't been actuated by the severingunit in the predetermined amount of time, T20 automatically lifts thesevering unit. T11 can only be actuated if a core is at the cuttingposition.

The system can be run manually utilizing air switches D7, D8 (flowingthrough V11), D3, D4, D5, D6 and D1. To reset to automatic after amanual run, air switch D9 is used. The air from D9 flows through airshuttle V12 to R3 and through air shuttle V13 to RS and R7, through airshuttle V10 and V8 to T8, R6, R9, R10 and R11 and through air shuttle V7and V16 to R8.

To set the system in a mode for a manual hand-cut and hand-overlap typestart on a core when the rest of the system is in automatic mode, SU isshifted to the bottom position. This takes the severing unit and PS-2out of the system by moving the arrows in T6 and T10 to the right andputs air at air relay R13. When air passes through T20 by operation ofthe cam sequencer which is still in the system, Rl3s arrow is moved tothe right and air flows to pressure-operated electrical switch PS-7causing its needle to move down and a predetermined rotation of theempty core and operation of the sheet forwarding means between theaccumulator unit and windup unit to begin via line 11-13. This allowsthe operator to make the manual cut and start. The normal automaticsequence begins again when the accumulator indicates via T14 that it isfull to a predetermined level. The sequence of operation is the same asdescribed above from that point except that PS-2 is not actuated, thesevering unit is not operated (remaining in its normal windingposition), andthe core rotates at its predetermined rate through itsmovement to the normal winding position and the lowering of the riderroll. Air from T16 causes the arrow in R13 to shift back to the right.

T21 is a safety device and is actuated, i.e., its arrow is shifted downwhen the accumulator is full as determined by the contact follower onspring-return air valve T21 which gets its air from the accumulatorsystem via X. The air from T21 passes through air shuttle V14 to PS-6and starts the empty core rotating at overspeed via 1-1-12. If there hasbeen a manual cut and start, T16 hasnt moved the arrow in R13 to theleft and T21 has been actuated, the arrow in R13 will be moved to theleftby the air from T21.

The above description is a description of a preferred embodiment of theinvention. Many variations and modifications within the spirit of theinvention will appear to those skilled in the art and such areconsidered to fall within the scope of the following claims.

The invention claimed is:

l. A system for automatic handling a running length of thermoplasticsheeting from a processing unit to form a series of individual rolls,said system comprising in combination and positioned along the generalpath of movement of the sheeting an accumulator unit cooperating withthe processing unit;

sheet forwarding means cooperating with the accumulator;

windup promotion means cooperating with the sheet forwarding means;

a windup unit cooperating with the windup promotion means, said windupunit comprising means for moving a core containing a certain length ofsheeting away from the general path of movement of the sheeting andreplacing said core containing a certain length of sheeting with anempty core after moving the core containing a certain length of sheetingaway from the general path of movement of the sheeting thereby unwindingsome sheeting from the core containing a certain length of sheeting andmoving the empty core towards the general path of movement until theempty core overlaps the sheeting and is in position to engage a severingunit; a severing unit cooperating with windup unit and positioned alongthe general path of movement of the sheeting, said severing unitcomprising in combination (a) a severing wire for severing the sheetingand heat bonding the end of the running length of sheeting to the emptycore, (b) means for heating said severing wire, (c) means for movingsaid severing wire, ((1) means for holding the severing wire inoperative association with the sheeting and empty core during severingand heat bonding, (e) means for clamping said end of sheeting to saidempty core, a positioning means for moving said severing unit intocontact or away from the sheeting where it overlaps the empty core, and(f) means for cooling the severed end of the running length of sheetingwhich is heat bonded to the empty core; and control means cooperatingwith said accumulator, sheet forwarding means, windup promotion means,windup unit and severing unit to cause the accumulator unit to collectthe sheeting from the processing unit which continues to operate whilethe core containing a certain length of sheeting is automatically movedfrom the general path of movement of the sheeting while the empty coreis moved toward the general path of movement of the sheeting until itoverlaps the sheeting, the sheet severed, the end of the running lengthof sheeting heat bonded to the empty core and the empty core moved intothe general path of movement of the sheeting, said control meanscomprising in combination (a) a footage counting means which determineswhen a certain length of sheeting has accumulated on said core, (b)means for actuating the accumulator unit such that the accumulator unitbegins to collect the sheeting from the processing unit when the footagecounting means indicates a certain length of sheeting is on the core,(c) means for ceasing the movement of the sheet forwarding means betweenthe accumulator unit when the footage counting means indicates a certainlength of sheeting is on the core, (d) means for actuating the winduppromotion means when the footage counting means indicates that a certainlength of sheeting has accumulated on the core and moving the winduppromotion means away from the general path of movement of the sheeting.(e) means for detecting when said moving of the windup promotion meansis in position for a core change, (f) means for actuating the windupunit so that the core containing a certain length of sheeting is movedaway from the general path of movementof the sheeting, unwound to adegree such that the core containing a certain length of sheeting can bemoved out of the general path of movement and the empty core movestowards the general path of movement when the means for actuating thewindup promotion means indicates that the windup promotion means is inposition for a core change,

(g) means for stopping the movement of the windup unit when the emptycore is in position under the severing unit, (h) means for causing thewindup unit to rotate or cease to rotate the empty core when the emptycore is positioned under the severing unit, (i) means for causing themeans for moving the severing wire into operative association with theempty core and overlapping sheeting to move the severing wire intooperative association with the empty core and sheeting when the emptycore has ceased to rotate, (j) means for holding the severing wire inoperative association with the sheeting and empty core when the severingwire has contacted the sheeting which is in contact with the empty core,(k) means for causing the means for heating the severing wire to heatwhen the means for holding the severing wire in operative associationwith the sheeting and the empty core are in position (1) means forcausing the means for holding and the means for moving the severing wireto move the severing wire from operative association with said sheetingand empty core while the means for holding said severing wire inoperative association with the sheeting and empty core continues to holdthe sheeting to the empty core so that the means for cooling the severedend of the running length of sheeting which is heat bonded to the emptycore can operate effectively when the heating means have heated thesevering wire for a predetermined amount of time and the heating hasceased, (m) means for causing said clamping means to hold said severedend to the empty core when said severing wire is in operative assocationwith the sheeting, (n) means for starting said means for cooling thesevered end of the running length of sheeting which is heat bonded tothe empty core, to cool after the means for holding and means for movingthe severing wire have moved the severing wire from operativeassociation with the sheeting and empty core, (0) means for causing thesevering unit and the means for holding the severing wire in operativeassociation with the sheeting and empty core to move away from thegeneral path of movement and into their positions for normal winding,(p) a filling detector means which indicates the level of accumulatedsheeting the accumulator unit, (q) means for causing the cooling to stopcooling when the accumulator is filled to a certain degree, (r) meansfor causing the means for clamping the severed end to release when thecooling is stopped, (s) means for causing the windup unit to move theempty core into normal winding position when said severing unit is innormal winding position, (t) means for causing the windup unit to rotatesaid empty core at least one revolution while said windup unit is movingthe empty core to the normal winding position. (u) means for causing thewindup promotion means to move to the general path of movement of thesheeting to the normal winding position when the empty core is in normalwinding position, (v) means for causing the sheet forwarding means tocommence operation when the windup promotion means is in normal windingposition, (w) means for causing the windup unit to cause the empty coreto rotate at a speed above normal winding speed such that theaccumulated sheeting in said accumulator unit is depleted when thewindup promotion means is in normal windup position, (x) means forcausing the windup unit to rotate the empty core at normal winding speedwhen said accumulator unit no longer contains any accumulated sheeting.

1. A system for automatic handling a running length of thermoplasticsheeting from a processing unit to form a series of individual rolls,said system comprising in combination and positioned along the generalpath of movement of the sheeting an accumulator unit cooperating withthe processing unit; sheet forwarding means cooperating with theaccumulator; windup promotion means cooperating with the sheetforwarding means; a windup unit cooperating witH the windup promotionmeans, said windup unit comprising means for moving a core containing acertain length of sheeting away from the general path of movement of thesheeting and replacing said core containing a certain length of sheetingwith an empty core after moving the core containing a certain length ofsheeting away from the general path of movement of the sheeting therebyunwinding some sheeting from the core containing a certain length ofsheeting and moving the empty core towards the general path of movementuntil the empty core overlaps the sheeting and is in position to engagea severing unit; a severing unit cooperating with windup unit andpositioned along the general path of movement of the sheeting, saidsevering unit comprising in combination (a) a severing wire for severingthe sheeting and heat bonding the end of the running length of sheetingto the empty core, (b) means for heating said severing wire, (c) meansfor moving said severing wire, (d) means for holding the severing wirein operative association with the sheeting and empty core duringsevering and heat bonding, (e) means for clamping said end of sheetingto said empty core, a positioning means for moving said severing unitinto contact or away from the sheeting where it overlaps the empty core,and (f) means for cooling the severed end of the running length ofsheeting which is heat bonded to the empty core; and control meanscooperating with said accumulator, sheet forwarding means, winduppromotion means, windup unit and severing unit to cause the accumulatorunit to collect the sheeting from the processing unit which continues tooperate while the core containing a certain length of sheeting isautomatically moved from the general path of movement of the sheetingwhile the empty core is moved toward the general path of movement of thesheeting until it overlaps the sheeting, the sheet severed, the end ofthe running length of sheeting heat bonded to the empty core and theempty core moved into the general path of movement of the sheeting, saidcontrol means comprising in combination (a) a footage counting meanswhich determines when a certain length of sheeting has accumulated onsaid core, (b) means for actuating the accumulator unit such that theaccumulator unit begins to collect the sheeting from the processing unitwhen the footage counting means indicates a certain length of sheetingis on the core, (c) means for ceasing the movement of the sheetforwarding means between the accumulator unit when the footage countingmeans indicates a certain length of sheeting is on the core, (d) meansfor actuating the windup promotion means when the footage counting meansindicates that a certain length of sheeting has accumulated on the coreand moving the windup promotion means away from the general path ofmovement of the sheeting, (e) means for detecting when said moving ofthe windup promotion means is in position for a core change, (f) meansfor actuating the windup unit so that the core containing a certainlength of sheeting is moved away from the general path of movement ofthe sheeting, unwound to a degree such that the core containing acertain length of sheeting can be moved out of the general path ofmovement and the empty core moves towards the general path of movementwhen the means for actuating the windup promotion means indicates thatthe windup promotion means is in position for a core change, (g) meansfor stopping the movement of the windup unit when the empty core is inposition under the severing unit, (h) means for causing the windup unitto rotate or cease to rotate the empty core when the empty core ispositioned under the severing unit, (i) means for causing the means formoving the severing wire into operative association with the empty coreand overlapping sheeting to move the severing wire into operativeassociation with the empty core and sheeting when the empty core hasceased to rotate, (j) means for holding the severing wire in operativeassociation with the sheetIng and empty core when the severing wire hascontacted the sheeting which is in contact with the empty core, (k)means for causing the means for heating the severing wire to heat whenthe means for holding the severing wire in operative association withthe sheeting and the empty core are in position (l) means for causingthe means for holding and the means for moving the severing wire to movethe severing wire from operative association with said sheeting andempty core while the means for holding said severing wire in operativeassociation with the sheeting and empty core continues to hold thesheeting to the empty core so that the means for cooling the severed endof the running length of sheeting which is heat bonded to the empty corecan operate effectively when the heating means have heated the severingwire for a predetermined amount of time and the heating has ceased, (m)means for causing said clamping means to hold said severed end to theempty core when said severing wire is in operative assocation with thesheeting, (n) means for starting said means for cooling the severed endof the running length of sheeting which is heat bonded to the emptycore, to cool after the means for holding and means for moving thesevering wire have moved the severing wire from operative associationwith the sheeting and empty core, (o) means for causing the severingunit and the means for holding the severing wire in operativeassociation with the sheeting and empty core to move away from thegeneral path of movement and into their positions for normal winding,(p) a filling detector means which indicates the level of accumulatedsheeting the accumulator unit, (q) means for causing the cooling to stopcooling when the accumulator is filled to a certain degree, (r) meansfor causing the means for clamping the severed end to release when thecooling is stopped, (s) means for causing the windup unit to move theempty core into normal winding position when said severing unit is innormal winding position, (t) means for causing the windup unit to rotatesaid empty core at least one revolution while said windup unit is movingthe empty core to the normal winding position, (u) means for causing thewindup promotion means to move to the general path of movement of thesheeting to the normal winding position when the empty core is in normalwinding position, (v) means for causing the sheet forwarding means tocommence operation when the windup promotion means is in normal windingposition, (w) means for causing the windup unit to cause the empty coreto rotate at a speed above normal winding speed such that theaccumulated sheeting in said accumulator unit is depleted when thewindup promotion means is in normal windup position, (x) means forcausing the windup unit to rotate the empty core at normal winding speedwhen said accumulator unit no longer contains any accumulated sheeting.